2002 CHEVROLET SUBURBAN Fuel System, Gasoline Problems

VEHICLE WILL STALL ON OCCASION WHILE DRIVING DOWN THE ROAD. ACTS AS IF THE ACCELERATOR IS NOT WORKING CAUSING THE VEHICLE TO COME TO A STOP WHILE TRYING TO APPLY THE ACCELERATOR PEDAL. THIS HAS HAPPENED AT LEAST 3 OTHER TIMES SINCE PURCHASING THE VEHICLE NEW. THE FIRST INCIDENT HAPPENED AT ABOUT 10,000 MILES ON THE VEHICLE AND THE LAST INCIDENT HAPPENED WITH A LITTLE OVER 120,000. *TR

Mileage: 120,000

SINCE PURCHASING AN 02 CHEVROLET SURBURBAN, 8.1L AND 81K MILES, I HAVE EXPERIENCED MULTIPLE RANDOM ENGINE SHUT OFFS WHILE HIGHWAY DRIVING, CREATING DANGEROUS SAFETY SITUATIONS. THE MOTOR WILL RESTART AFTER A 5 MINUTE REST PERIOD AND RUN FINE, UNTIL THE NEXT FAILURE WHICH OCCURS WITHOUT WARNING. THE DEALERSHIP HAS SO FAR BEEN UNABLE TO DIAGNOSE THE PROBLEM, CLEANED MAF SENSOR, REPLACED THERMOSTAT AND FAN CLUTCH, CHANGED OIL, CHECKED FUEL PUMP PRESSURE. NO ENGINE FAILURE CODES REPORTED. RESEARCHING INTERNET INFORMATION, I HAVE DISCOVERED A RECURRING SYMPTOM RELATED TO AN INTERMITTENT CRANKSHAFT POSITION SENSOR (CKP) FAILURE, THAT CAUSES THE ENGINE TO SHUT OFF. THERE IS A A TIMED RESET WHICH ALLOWS THE ENGINE TO RESTART. *TR

Mileage: 87,620

DT*: THE CONTACT STATED WHILE DRIVING ON THE HIGHWAY AT 20 MPH AND PULLING UP TO A TOLL BOOTH, THE VEHICLE STALLED SUDDENLY WITHOUT WARNING. THE VEHICLE WAS TOWED TO A DEALERSHIP WHERE THE DEALERSHIP DETERMINED THE VEHICLE NEEDED A NEW IGNITION SWITCH. WHILE DRIVING BACK HOME THE VEHICLE STALLED AGAIN. THE VEHICLE WAS TOWED 100 MILES TO A DEALERSHIP WHERE THE DEALERSHIP DETERMINED THE VEHICLE HAD A FAULTY FUEL PUMP. THE DEALERSHIP INFORMED THE CONTACT THERE WAS A HISTORY OF FAULTY FUEL PUMPS WITH THIS YEAR, MAKE AND MODEL.

Mileage: 69,000

I HAVE A 2002 SUBURBAN THAT HAD A RECALL FOR THE GAS TANK LEAKING WHEN IT IS FILLED PAST 3/4 FULL. THE RECALL WORK WAS DONE IN DECEMBER 2005. THEN IN MARCH I SMELT GAS AGAIN I NOTICED A LARGE PUDDLE WAS UNDER MY VEHICLE AS I PULLED OUT OF THE GARAGE. I CARRIED IT BACK IN AND THEY CHARGED ME $890.00 AND STATED SINCE THE RECALL WORK WAS DONE IN DECEMBER THIS WOULD NOT BE COVERED. I HAVE THE PARTS THEY REPLACED. *JB

Mileage: 140,000

2002 CHEVROLET SUBURBAN THAT STALLS INTERMITTENTLY WHILE DRIVING DOWN THE ROAD. THIS HAS HAPPENED SEVERAL TIMES IN THE PAST TWO WEEKS. WE TOOK IT INTO THE SERVICE CENTER WHERE THEY HAVE TOLD US THAT THE FUEL PUMP WILL NEED TO REPLACED AT A COST OF OVER $700. THERE IS CURRENTLY A RECALL ON 2001 MODELS WITH THE EXACT SAME PROBLEM. *NM

Mileage: 87,340

MY WIFE AND I HAVE BEEN VERY HAPPY WITH THE VEHICLE UNTIL A SITUATION LAST YEAR. SPECIFICALLY, THERE IS A KNOWN PROBLEM WITH THE GAS TANK AND GAUGE. THE GAS TANK WILL BE A 1/4 FULL BUT THE CAR WILL NOT START BECAUSE IT THINKS THE GAS TANK IS EMPTY. MY LOCAL GM DEALER SERVICE CENTER QUOTED ME OVER $800 TO FIX THIS PROBLEM. IT IS A KNOWN GM DEFECT. GM'S TECHNICAL SOLUTION IS DOCUMENT ID # 1575648. IT READS: VEHICLE WITH FLEXIBLE FULE (RPO L59) WILL NOT START, STALLS AND WILL NOT RESTART, LOSS OF POWER, POOR PERFORMANCE, AND /OR FUEL GUAGE READS INACCURATE/INCORRECT (REPLACE FUEL SENDER/MODULE ASSEMBLY) #04-06-04-012B - (DEC 6, 2004) * REPLACE FUEL SENDER /MODULE ASSEMBLY WITH REDESIGNED FUEL STRAINER AND /OR REDSIGNED FUEL LEVEL SENOR CAN YOU PLEASE HELP ? THANKS, BRENDAN AND LISA O'REILLY. *NM

Mileage: 72,700

DURING EVACUATION FOR HURRICANE RITA AS WE WERE PROCEEDING IN TRAFFIC OUR 2002 CHEVY SUBURBAN JUST DIED. IT WAS AS IF IT WAS GETTING NO FUEL. WE HAD A FULL TANK. THE RPM AND POWER STEERING ALONG WITH THE ENGINE JUST WENT DEAD. SINCE THE HURRICANE I HAVE TALK TO 3 OTHER PEOPLE WITH SUBURBANS OR YUKONS THAT THIS HAPPEN TO. THE DEALERSHIP SAID IT WAS THE FUEL PUMP. I NOW THINK SOMETHING IS WRONG WITH THESE VEHICLES. I HAVE THE FUEL PUMP TAKEN FROM MY SUBURBAN. *NM

Mileage: 43,000

PURCHASED A NEW 2002 SUBURBAN K2500 IN AUG OF 2002. AT 17,000 MILES, THE AIR CONDITIONING WENT OUT. DEALER REPLACED THE COMPRESSOR. AT 27,000 MILES, THE FUEL GAUGE SHOWED EMPTY WHEN THE TANK WAS FULL. DEALER REPLACED REAR FUEL TANK SENDING UNIT. AT 55,000 MILES, THE FUEL TANK AGAIN SHOWED EMPTY WITH A FULL TANK AND THE ENGINE SURGED. THE DEALER (BOB STEELE IN COCOA FL) REPLACED THE FUEL PUMP IN THE REAR TANK AND THE SENDING UNIT IN THE FRONT TANK UNDER MY EXTENDED WARRANTY WITH A DEDUCTIBLE. DEALER STATED THIS WAS NOT A RECURRENCE OF THE PROBLEM BEFORE. AT 58,000 MILES THE CAR STALLED WHILE CROSSING OVER A BUSY BRIDGE/CAUSWAY AT APPROX. 60 MPH. "REDUCED ENGINE POWER" GLARED ON THE WARNING INDICATOR, POWER STEERING WAS LOST AND LIGHTS ON THE DASH WERE FLASHING ERRATICALLY. LUCKILY, I HAD CRESTED THE TOP OF THE CAUSWAY AND MANAGED TO STEER TO THE TINY SHOULDER WITHOUT CRASHING INTO ANYBODY. THE CAR WOULD NOT START IMMEDIATELY, BUT AFTER TRYING FOR FIFTEEN MINUTES I WAS ABLE TO GET IT STARTED AND DRIVE HOME. I CALLED THE DEALER (IT WAS FIVE MINUTES TO CLOSING TIME) AND WAS TOLD TO BRING IT IN THE NEXT DAY. IT STALLED AGAIN AT A TRAFFIC LIGHT ON THE WAY TO THE DEALER BUT STARTED IMMEDIATELY. THE DEALER REPLACED THE THROTTLE POSITION SENSOR UNDER MY EXTENDED WARRANTY WITH DEDUCTIBLE AND AGAIN STATED THAT NONE OF THESE FUEL/STALLING PROBLEMS WERE RELATED. THE CAR STALLED AGAIN RECENTLY AND THE DEALER SAID TO BRING IT IN IF IT HAPPENS AGAIN. THIS IS STARTING TO BECOME A VERY DANGEROUS SITUATION THAT THE DEALER SEEMS TO BE VERY UNCONCERNED ABOUT. *NM

Mileage: 58,000

DT: CONTACT OWNED A 2002, CHEVROLET SUBURBAN. HE FILED A COMPLAINT BEFORE, AND HIS ODI NUMBER WAS 10099685. WHILE DRIVING VEHICLE COMPLETELY SHUT DOWN. CONSUMER HAD TO WAIT FOR ABOUT 15 MINUTES BEFORE STARTING IT AGAIN. CONSUMER STATED THAT HE HAD THIS PROBLEM SINCE PURCHASING THE VEHICLE. IT STALLED INTERMITTENTLY. CONSUMER HAD THE FUEL PUMP REPLACED A TOTAL OF FIVE TIMES. ALSO, FUEL FILTER HAD TO BE REPLACED SEVERAL TIMES. CONSUMER STATED THAT ONSTAR CALLED THE PROBLEM CODE RED. CONSUMER WAS TOLD NOT TO DRIVE THE VEHICLE. AT 70 MPH THE VEHICLE WOULD SURGE AND LURCH. CONSUMER STATED THAT A CLANKING NOISE WAS HEARD WHEN TURNING A TIGHT CORNERS. ALSO, THERE WAS AN ADDITIONAL INCIDENT ON 8-26-04.*AK

DT: CONTACT OWNED A 2002, CHEVROLET SUBURBAN. HE FILED A COMPLAINT BEFORE, AND HIS ODI NUMBER WAS 10099685. WHILE DRIVING VEHICLE COMPLETELY SHUT DOWN. CONSUMER HAD TO WAIT FOR ABOUT 15 MINUTES BEFORE STARTING IT AGAIN. CONSUMER STATED THAT HE HAD THIS PROBLEM SINCE PURCHASING THE VEHICLE. IT STALLED INTERMITTENTLY. CONSUMER HAD THE FUEL PUMP REPLACED A TOTAL OF FIVE TIMES. ALSO, FUEL FILTER HAD TO BE REPLACED SEVERAL TIMES. CONSUMER STATED THAT ONSTAR CALLED THE PROBLEM CODE RED. CONSUMER WAS TOLD NOT TO DRIVE THE VEHICLE. AT 70 MPH THE VEHICLE WOULD SURGE AND LURCH. CONSUMER STATED THAT A CLANKING NOISE WAS HEARD WHEN TURNING A TIGHT CORNERS. ALSO, THERE WAS AN ADDITIONAL INCIDENT ON 8-26-04.*AK

WHILE DRIVING VEHICLE COMPLETELY SHUT DOWN. CONSUMER HAD TO WAIT FOR ABOUT 15 MINUTES BEFORE STARTING IT AGAIN. CONSUMER STATED THAT HE HAD THIS PROBLEM SINCE PURCHASING THE VEHICLE. IT STALLED INTERMITTENTLY. CONSUMER HAD THE FUEL PUMP REPLACED A TOTAL OF FIVE TIMES. ALSO, FUEL FILTER HAD TO BE REPLACED SEVERAL TIMES. *AK THE CONSUMER STATED THAT ONSTAR CALLED THE PROBLEM CODE RED. CONSUMER WAS TOLD NOT TO DRIVE THE VEHICLE. AT 70 MPH THE VEHICLE WOULD SURGE AND LURCH. THE CONSUMER STATED THAT A CLUNKING NOISE IS HEARD WHEN TURNING TIGHT CORNERS. *TC

(1) THE ENGINE STOPPED WHILE ON INTERSTATE IN CONSTRUCTION ZONE ON SLIGHT HILL, IT WOULD NOT RESTART. (2) THE CONSTRUCTION ZONE ON INTERSTATE 10 WAS APPROXIMATELY 3 MILE LONG WITH VERY NARROW LANES AND CONCRETE CONSTRUCTION BARRIERS ON EACH SIDE & NO SHOULDERS. BUMPER TO BUMPER TRAFFIC AND NO WAY TO CLEAR THE LANE OR GET TOW VEHICLE. (3) A GOOD SAMARITAN TOWED OUR VEHICLE ABOUT 2 MILES TO FIRST POINT CLEAR TRAFFIC. CHEVY DEALER CONFIRMED FUEL PUMP IN TANK HAD FAILED & REPLACED PUMP. THIS WAS SECOND PUMP FAILURE. THE PUMP PREVIOUSLY FAILED AND WAS REPLACED ON 30 AUG 03. PREVIOUS FAILURE DEALER SAID KEEP FUEL ABOVE 25% & ENGINE WOULD RUN. THE TANK WAS AT 44% WHEN ENGINE QUIT. FUEL TANK WAS TOPPED OFF BEFORE PUMP TESTED, ENGINE WOULD RUN BUT NO PUMP PRESSURE. SOMEONE WILL BE KILLED IF MORE FAILURES OCCUR IN HEAVY TRAFFIC AREAS. THE EMERGENCY GOOD SAMARITAN TOW OUT OF THE CONSTRUCTION AREA PREVENTED A SERIOUS ACCIDENT AS IT WAS GETTING DARK.*AK

Mileage: 74,587

2 SECONDS AFTER STARTING THE VEHICLE IT STALLED. THEN, CONSUMER RESTARTED THE VEHICLE, AND THE FAILURE RECURRED WITHIN 2 SECONDS. DEALERSHIP INDICATED THAT THEY HAD A LOT OF COMPLAINTS ON THIS ISSUE, AND IT COULD BE DUE TO FUEL INJECTION OR FUEL PUMP PROBLEMS. DEALERSHIP PERFORMED A DIAGNOSTIC TEST, BUT NOT FAILURE WAS FOUND. *AK

Mileage: 5,000

2 SECONDS AFTER STARTING THE VEHICLE IT STALLED. THEN, CONSUMER RESTARTED THE VEHICLE, AND THE FAILURE RECURRED WITHIN 2 SECONDS. DEALERSHIP INDICATED THAT THEY HAD A LOT OF COMPLAINTS ON THIS ISSUE, AND IT COULD BE DUE TO FUEL INJECTION OR FUEL PUMP PROBLEMS. DEALERSHIP PERFORMED A DIAGNOSTIC TEST, BUT NOT FAILURE WAS FOUND. *AK

Mileage: 5,000

DURING COLD WEATHER SEASONS, AFTER STARTING THE VEHICLE, THE CONSUMER SMELLED GAS FUMES INSIDE THE VEHICLE. THE CAUSE HAS YET TO BE DETERMINE. THE DEALERSHIP WAS NOTIFIED BUT DID NOT RESOLVE THE PROBLEM. *NM

Mileage: 54,900

MY 2002 CHEVROLET SUBURBAN WILL NOT START ONCE THE GAS TANK GETS BELOW 1/4 FULL. I PARK IN MY DRIVEWAY THAT HAS A SLIGHT SLOPE TO THE STREET AND IT DOES NOT MATTER WHICH WAY I PULL THE VEHICLE IN, IT WILL NOT START WITH A LOW (LESS THAN 1/4 TANK) AMOUNT OF GAS IN THE TANK. I HAVE SPOKE TO THE SERVICE MANAGER AT THE CHEVROLET DEALERSHIP AND HE INFORMS ME THAT CHEVY HAS NOT NOTIFIED HIM THAT THEIR IS A PROBLEM. I HAVE SPOKE TO ONE OTHER PERSON AND HE HAS THE EXACT SAME PROBLEM WITH HIS SUBURBAN OF THE SAME YEAR. THERE IS A PROBLEM AND I BELIEVE IT TO BE SOMETHING WITH THE FUEL PICKUP DESIGN IN THESE VEHICLES. I HAVE HEARD OF NO RECALL, OR ATTEMPT TO CORRECT THIS, BECAUSE IT PROBABLY WOULD BE VERY COSTLY TO GM. IT IS A LARGE INCONVENIENCE TO ME AND HAS HAPPENED MORE THAN FOUR TIMES. *LA

WHEN DRIVING AT 60MPH IN HEAVY TRAFFIC THE ENGINE QUIT RUNNING TWICE IN LESS THAN 20 MILES. THE DEALER SAID IT WAS DUE TO DEFECTIVE FUEL PUMP AND THE DESIGN OF THE FUEL PUMP AND GAS TANK, WHICH THEY SAID COULD NOT BE FIXED. VEHICLE HAD MORE THAN 1/2 GAS FULL IN ITS TANK. ON SEVERAL OTHER OCCASIONS, THE CAR WOULD NOT START EVEN WITH A 1/4 TANK OF GAS. I WAS TOLD BY DEALER NOT TO LET THE TANK GET LESS THAN 1/4 FULL. THE DEALER REPLACED THE FUEL PUMP 3 TIMES, AND THE CAR HAS LESS THAN 20,000 MILES ON IT. *LA

Mileage: 17,000

2002 SUBURBAN Z71. THE FUEL FILTER ON THE VEHICLE IS NOT THE FILTER REFERENCED FOR THE VEHICLE IN THE OWNERS MANUAL. WE WERE TOLD THAT DUE TO AN ENGINEERING OVERSIGHT, THE FILTER WAS CHANGED TO THE ONE WE HAVE. THE PROBLEM EXISTS IN THAT QUICK DISCONNECT IS TOO CLOSE TO THE FILTER HOUSING, AND THE NORMAL REMOVAL TOOL CANNOT BE USED TO REMOVE THE FILTER. GM SERVICE PERSONNEL WILL TELL YOU OFFLINE, THAT THE BEST METHOD FOR REMOVAL IS SAWING OFF THE FILTER OR CRIMPING IT OFF. WITH THE GM CUSTOMER SERVICE ON THE LINE - THEY ARE REQUIRED TO TELL YOU THAT A SPECIAL TOOL NOT AVAILABLE IN AUTOMOTIVE STORES MUST BE USED TO REMOVE THE FILTER. WE FINALLY RECEIVED A REFERENCE TO THE SOLE MANUFACTURER OF THE $35 DOLLAR PLASTIC TOOL. THE TOOL ONLY WORKS BY FORCING 4 PIECES OF PLASTIC THROUGH THE SMALL SPACE AND THE UP THE NECK. AS STATED, OFF LINE, THE MECHCANIC WILL TELL YOU THAT THEY CUT OR SAW IT OFF, AND DIG THE FILTER NECK OUT OF THE DISCONNECT. THE PROBLEM IS OBVIOUS, BUT THE SOLUTION IS IMPOSSIBLE. THE HAZARD IS THAT THE TRUE MECHANIC RECOMMENDATION RESULTS IN CUTTING METAL ON A GAS LINE. IN ADDITION, WITH IT BEING ON THE OUTBOARD SIDE, ON FRAGMENTS ENTER DIRECTLY INTO THE ENGINE.*JB

CONSUMER STATES THE CAN'T GET NO GAS AT ALL DUE TO FUEL TANK IS NOT VENTILATE. DEALER NOTIFIED MANY TIMES. PLEASE PROVIDE FURTHER INFORMATION. *TR

WHEN THE VEHICLE WAS REFUELED, FUEL SPILLED ONTO THE GROUND. *JB

WHEN FILLING THE GAS TANK, THE PUMP CUTS OFF AT 3/4 FULL. WHEN I TRY TO FILL IT ALL THE WAY, IT OVER FLOWS ONTO THE GROUND AFTER THE PUMP CUTS OFF AGAIN. THE DEALER (TEAM CHEVROLET) SAYS THERE IS NOTHING WRONG WITH THE TANK. THEY SAY IT IS THE GAS STATION I AM USING OR I SHOULD JUST HOLD THE GAS NOZZLE MYSELF UNTIL IT IS FULL. *JB

Mileage: 3,000

THEY REALLY SHOULD FIX. NO SAFETY DEFECT LISTED. *AK

AFTER FUELING VEHICLE THE NIGHT BEFORE THERE WAS A PUDDLE OF FUEL UNDERNEATH VEHICLE, THE NEXT DAY THE VEHICLE WAS TAKEN TO THE DEALER WHO SAD IT WAS CAUSED BY A DEFECT IN THE FUEL TANK.*AK *MJ

CONSUMER STATES THAT FUEL TANK ASSEMBLY HAS A MALFUNCTION. WHEN CONSUMER IS PUTTING FUEL INTO HIS VEHICLE THE NOZZLE AT THE GAS STATION KEEP CUTTING OFF, WHICH INDICATES THAT THE TANK IS FULL, BUT THE TANK ISN'T. SO YOU HAVE TO KEEP FUELING AND ESITMATING WHEN THE TANK IS FULL. NLM

I HAVE BEEN UNABLE, SINCE PURCHASE, TO PROPERLY FILL THE GAS TANK. THE TANKS HAVE BEEN REPLACED, THE FILLER MECHANISM HAS BEEN REPLACED. GMC ACKNOWLEDGES THAT THER IS A PROBLEM BUT SIX MONTHS AFTER FIRST IDENTIFYING THE PROBLEM, THEY SAY THEY STILL DONT HAVE A FIX. I SEE FROM CHECKING CONSUMER COMPLAINTS THAT OTHER OWNERS ARE EXPERIENCING THE SAME DIFFICULTIES AND ARE CONCERNED ABOUT THE POSSIBILITY OF GAS FUME BUILDUP AND POSSIBLE EXPLOSION.*AK